EP1691131B1 - Exterior lamp in a vehicle and method of manufacturing such an exterior lamp - Google Patents

Abstract

The vehicle external lamp has a lamp body which is formed by a cast body made of insulating cast mass. The light source and the wires are surrounded by the cast body essentially free from hollow spaces and the cast mass is transparent in a main direction of light emission of the light source. An independent claim is also included for method for the production of vehicle external lamp.

Description

The invention relates to a vehicle exterior light and a method for producing such a vehicle exterior light

The lamp body of vehicle exterior lights typically consist of a light panel and a housing bottom, which together form a housing enclosing a cavity. Through a cable feedthrough in the housing bottom, an at least two-wire line for electrical control and supply of a light source inside the housing is performed.

In the cavity of a lamp housing and several lights can be accommodated with separate light sources for different functions. For example, for a tail light assembly rear light, brake light and turn signals can be accommodated in a common housing. It turns out that the known vehicle lights in the long term often have leaks and thus functional failures occur.

At one of the DE 203 04 930 U1 known vehicle lamp is used as a light source LED with PUR material in a trough of the housing bottom, so that only the light emitting surface of the diode lens on the PUR material protrudes into the cavity of the housing. The housing joint between the lens and the housing base is encapsulated in a mold.

The DE 10 232 894 A1 describes a motor vehicle lamp in which a light-emitting diode is arranged on a flexible conductor and is cast together with this in an elastic transparent plastic potting compound which forms a lamp body with a curved light exit surface. A reflector for the light emitted by the light emitting diode is also included in the potting compound.

The US Pat. No. 6,739,733 B1 describes a rupture resistant LED lamp and a method for its manufacture. In this case, a circuit carrier with a plurality inserted by light emitting diodes in a mold. The mold is filled with a liquid plastic potting compound, which forms a transparent lamp body after solidification and is removed from the mold.

Fully potted light arrangements with incandescent lamps or light-emitting diodes in transparent flexible plastic are known per se as decorative illuminations, in particular as so-called light tube arrangements or light bands. Depending on the type of control effects, z. B. monochrome, multicolor, running light can be provided for driving and power supply of the light sources two or more wires. The technique of sheathing is at least partially known in principle to those skilled in, z. B. from the DE 696 32 848 T2 ,

The invention has for its object to provide an advantageous vehicle exterior light and a method for producing such.

Solutions according to the invention are described in the independent claims. The dependent claims contain advantageous refinements and developments of the invention.

The embodiments of the lamp body, which contains the at least one electronic light source and the line arrangement, as a potting of an insulating potting compound, which encases light source and lines substantially void-free, surprisingly leads to a considerable despite the loss heat dissipation and thereby typically higher operating temperature of the light source reduced failure rate of such vehicle exterior lights. The invention makes use of the finding that in conventional vehicle lights failures are primarily caused by leaks in the lamp housing soft, inter alia, due to the fact that by strong temperature fluctuations, eg. B. by changing sunlight on the lamp, occur in Leuchteninnem significant pressure fluctuations and cause a pumping effect, through which moisture passes through despite seals existing or over time resulting small leakage paths inside.

To produce such a luminaire, in a first advantageous variant, the light source with a line arrangement is inserted into a casting mold and encased with potting compound. The potting compound may, for. B. are introduced as a thermoplastic material under elevated pressure and / or elevated temperature by injection molding in the mold or filled as a castable, preferably low-viscosity mass and solidified in the mold. The mold determines after solidification of the potting compound the outer shape of the finished lamp body.

The mold is at least partially formed by a prefabricated housing part, which remains firmly connected to the finished lamp body with the potting compound and forms part of the surface of the lamp body.

According to another manufacturing variant of the lamp body is produced by extrusion, wherein the light source and line assembly are guided during the extrusion through the extrusion nozzle assembly and encircled by the extruded potting compound. This is in particular for producing elongated coherent lamp body, in particular for a band-shaped lamp body, which as a light source in the longitudinal direction spaced from each other more than the user as a single luminaire or light strip appearing bulbs, especially light-emitting diodes containing, advantage. But it can also be produced in an extrusion process several lights connected, which are subsequently cut off and separated as sections of the extruded strand. The light sources and line arrangements to a luminaire or to individual luminaires of such a luminaire composite can already be provided before the extrusion jacket with a connecting device, which is later exposed again.

In the manufacture of the lamp body of solidified potting more elements of the lamp, such. B. electrical connection elements or mechanical fasteners are included in the potting compound and also partially protrude from this. It can also further elements such. B. reflector devices are included in the potting.

The potting compound of the potting body is advantageously transparent at least in a main emission direction of the light source. Preferably, the entire potting body is material homogeneous. Light source and line arrangement are advantageously enclosed on all sides by potting compound, wherein leading to the outside electrical lines pass through the surface of the potting and there may be enclosed by an extension of the potting.

A part of the surface of the luminaire body is formed by a protective layer over the potting body which in particular may have a higher scratch resistance and / or a lower surface roughness. This protective layer is formed by a prefabricated housing part, which serves for the production of the potting body as part of the mold for the potting compound. Attachment devices for fastening the finished luminaire to a vehicle can also be prepared on such a housing part. The housing part can in advantageous embodiments, for. B. cup-shaped or formed as a profile strand.

The light source is preferably formed by one or more light-emitting diodes (LED) as light-emitting elements. Several functionally and spatially unitary light-emitting elements, such. B. an array of several LEDs are referred to as a light source. Belonging to the light source are also other included in the potting electronic components, such as resistors, converters, controllers, etc. understood. The conductor arrangement enclosed in the potting body can in particular contain electrical connection lines to the outside of the potting body for the operation of the light source. For the operation of the light source, it is also possible to provide strip conductors on a printed circuit board carrying a light-emitting element and / or further components as part of the line arrangement. The board can be made rigid or as a flexible film.

The several lines of the line arrangement or some of these lines can be advantageously already connected before encasing with the potting compound mechanically in a line carrier. The cable carrier can be made completely or partially rigid or flexible. In particular, for the production of a band-shaped elongated coherent flexible lamp body, z. As for a side marker lamp assembly, the conductor carrier may advantageously be designed as a flexible band.

In addition to the lines required for the operation of the respective luminaire or luminaires of the luminaire body, the line arrangement can contain further lines which are passed only through the luminaire body between a line input and a line output. Also, for the operation of the enclosed by the potting body light can be performed between a line input and a line output, so that a plurality of lamp body can optionally be electrically connected in succession with the interposition of cable sections of an electrical line source.

The outer shape is advantageously largely arbitrary. An advantageous embodiment provides that the lamp body is designed substantially prismatic with in a longitudinal direction approximately constant cross-sectional shape. This is particularly advantageous in connection with the production of a lamp body by extruding a potting compound and / or by using a prefabricated profile as part of the mold. In an advantageous embodiment, the luminaire body can have at least one, preferably at least two, laterally oppositely arranged projections facing away from the vehicle and pointing typically in the direction of the main emission direction of the luminaire, which project away from the vehicle beyond the irradiated surface and This can protect them against mechanical damage. It can also be provided around the irradiated surface circumferential projection.

For the attachment of the lamp to a vehicle fasteners can be included in the production of the potting of these in the way that they are accessible to finished luminaire body from the outside, for. B. as threaded sleeves or threaded bolts, as undercut receptacles for other fasteners or in the form of other, known in the art per se attachment types. The cast-over fastening elements can hold the components to be enclosed in a defined position in the mold during the casting process.

The lamp body can have laterally lying with respect to a main emission direction attachment areas in which mounting structures, such as breakthroughs or projections to be prepared or can be subsequently produced without affecting the lighting function. Such attachment structures may in particular also be formed on a housing part prepared as part of the casting mold.

For electrical contacting of the encapsulated conductor arrangement, it can be provided, for example, that lines lead to the outer surface of the potting body where they are electrically connected, preferably soldered, to leads from an electrical power source or to lines to or from other luminaires. Such leading to the outer surface of the potting body lines of Umtossenen line arrangement can be uncovered for this purpose by removing potting and electrically connected in the exposed areas. In another advantageous embodiment, a cable section can be electrically connected as a part of the line arrangement at a cast-end with the light source of the lamp, with other lines of the line arrangement, with other components and thereafter, wherein a free end of the cable section from the mold or the solidified cast body can be led out as a connection cable and connected in a conventional manner.

Also advantageous is an electrical connection by means of the insulating potting compound of the finished lamp body up to lines of the enclosed line arrangement of subsequently penetrating contact tips or contact blades. The lines of the line arrangement to be contacted in such a manner can be designed for this purpose in a different form from other lines of the line arrangement, in particular as a braid of thin wires, as a conductive polymer, etc. in the connection variant with tip or cutting contact through the solidified casting compound In the production of the potting body, the line arrangement can be completely encapsulated without lines leading to the outer surface of the potting body or through it. The to be contacted Cables can also be embedded in a softer insulating material than the potting material, which extends to the surface of the potting or is covered only by a thin layer potting or is released before contacting potting material.

Fig. 1

Teile einer ersten Leuchtenausführung mit topfförmiger Lichtscheibe,

Fig. 2

einen Schnitt durch eine vergossene Leuchte nach Fig. 1,

Fig. 3

Teile einer Leuchte mit Profil-Lichtscheibe,

Fig. 4

einen Schnitt durch eine vergossene Leuchte nach Fig. 3,

Fig. 5

eine Schrägansicht einer Leuchte ohne separate Lichtscheibe,

Fig. 6

die Leuchte nach Fig. 5 von der Rückseite,

Fig. 7

Teile einer weiteren vorteilhaften Ausführung,

Fig. 8

eine Seitenansicht einer Leuchte nach Fig. 7,

Fig. 9

einen bandförmig extrudierten Leuchtenkörper,

Fig. 10

eine Leuchtenanordnung mit Verbindungskabel,

Fig. 11

eine Leuchtenanordnung mit bandförmigem, durchgehendem Leuchtkörper.

The invention is illustrated below with reference to preferred embodiments with reference to the figures still in detail. Showing:

Fig. 1

Parts of a first lamp version with pot-shaped lens,

Fig. 2

a section through a potted light after Fig. 1 .

Fig. 3

Parts of a luminaire with profile lens,

Fig. 4

a section through a potted light after Fig. 3 .

Fig. 5

an oblique view of a lamp without a separate lens,

Fig. 6

the light after Fig. 5 from the back,

Fig. 7

Parts of a further advantageous embodiment,

Fig. 8

a side view of a light after Fig. 7 .

Fig. 9

a strip-shaped extruded luminaire body,

Fig. 10

a luminaire arrangement with connecting cable,

Fig. 11

a luminaire arrangement with band-shaped, continuous filament.

In Fig. 1 Parts of a first advantageous embodiment of a vehicle exterior light according to the present invention are outlined. The outer contour of the lamp is largely determined by a cup-shaped lens LS made of transparent material, which is preferably made as an injection molded part made of plastic. The lens LS consists essentially of a light exit surface LF and side walls SW. The side walls enclose in the example sketched oval-shaped interior. On the side walls, facing the interior spacers AH are provided to hold a light source assembly in a defined position within the multi-sided surrounded by the lens inner space. The interior space, which is surrounded on several sides by the light disk, is open in the direction away from the light passage surface LF. From this open side, a light source arrangement is inserted into the cavity, which has at least one light source on a circuit board PL1. Advantageously, the light source arrangement can have a plurality of individual light sources, which can be configured in particular as light-emitting diodes, which can also be assigned to different illumination functions within the vehicle light arrangement. The electronic light sources are arranged on the side of the board PL1 facing the light passage surface LF. Furthermore, further components such as series resistors, regulators or limiters for cooperation with the light sources can be provided on the circuit board PL1. The circuit board PL1 advantageously has electrical lines, in particular in the form of printed or etched strip conductors, which serve to connect the light sources to one another, to the other components and to an electrical supply line.

A connection cable KA is connected to the lines on the board PL1 and serves to control and electrical power supply of the light sources on the board. The connecting cable KA is outlined in the example shown on the front side, the light exit surface LF facing side of the board PL1 and fixed there, for example glued. The connecting cable KA has a plurality of wires insulated from each other, the number of which can depend on the number of different lighting functions on the board PL1. The cable KA is deflected in the example outlined from the front of the board PL1 to the rear.

On the back of the board PL1 a holding body BT is fixed, which carries two fasteners BE, such as bolts, which can be used to attach the finished lamp to a vehicle. The fasteners can also be used when potting the board to ensure the relative position of the board with respect to the cup-shaped lens until the solidification of potting material. For alternative attachment of the finished lamp fastening devices BV can also be provided on the lens LS, in particular protruding outwardly therefrom, which in the example outlined are designed as projections for inserting the luminaire into a retaining profile.

The board PL1 with cable KA, back carrier BT and fasteners BE is inserted into the cup-shaped lens LS and the cavity of the lens is filled substantially completely and void-free with a potting material, which both between board PL1 and light passage surface LF as well as on the light passage surface LF facing away from the board is taught and the cup-shaped lens LS fills substantially void-free and bubble-free. The potting material can be introduced as a thermoplastic material in an injection molding process or can be poured as a thin liquid material in the serving as a mold lens. The incorporation of the low-viscosity material can also be done in two steps, wherein in a first step, the empty mold partially filled with potting material, then the board with light source and cable used and finally the mold is filled with potting material.

After solidification of the potting material, a finished luminaire is present, in which the electronic light sources, the optionally present further electronic components and the electrical leads are cast permanently watertight. The potting material is advantageously chosen so that it forms adherent and Kriechwasserdichte interfaces with the lens and preferably also with the board, the cable KA and / or the carrier BT on the back of the board.

In Fig. 2 is cut open in oblique view from the front a ready potted luminaire of Fig. 1 sketched with components illustrated type. On the front side of the board, first light sources LQ11 for a first illumination function and second light sources LQ12 for a second illumination function of the vehicle exterior light are arranged. Potting material VM is located both between the board and the light exit surface LF and on the side facing away from the light exit surface LF side of the board. It can be seen that at the top and at the bottom of the board due to the spacers AH each a gap connects the two sub-volumes of the potting material, which is responsible for both the spreading of the potting material when introduced into the cup-shaped lens and for the permanent connection of the potting compound in the finished state is beneficial. The PCB PL1 can additionally breakthroughs in the Have board surface through which further material homogeneous compounds of the potting material can reach through.

At the in Fig. 3 sketched embodiment, in turn, a lens LP is provided as a limitation of the lamp in the main light emission direction. This lens LP is different from the Fig. 1 designed as a profile with in a longitudinal direction constant cross section, which may be designed as an injection molded part or in particular as an extruded profile. For the positioning of a board relative to the lens, centering devices, such as a stop shoulder AS, may be provided on the profile. From the position of the board facing away from the back side walls SW3 of the profile are provided. From these laterally outwardly projecting, in particular for fastening the finished lamp, fastening devices may be provided, for example in the form of mounting webs MS on the profile.

On a circuit board PL3, a plurality of light sources are again provided, which can be assigned to different illumination functions of a vehicle lighting arrangement. A multi-core cable KA is again attached to the front of the board and serves to control and electrical supply of the individual light sources via lines on the board. Another plate WS is made of good heat conducting material, such as aluminum, and is good heat conducting connected to the back of the board PL3, in particular glued. With sufficient stability of the plate WS, the board PL3 may also be formed with a particularly small thickness as a foil board or the like. The plate WS can also be present in a composite with the PL3 board. Instead of a plate PL3, a differently shaped element, for example a profile, may be provided of thermally conductive material.

Board PL3 and plate WS are used in a defined position in the formed as a profile lens LP, advantageously plate PL3 and plate WS extend over only a portion of the length of the profile LP and are present at both ends of the profile end portions, which not to the rear Board PL3 and / or plate WS are covered. The end portions are closed by further mold walls and potting material is introduced into the multi-sided surrounded by the profile LP interior space with the board and the plate WS and fills the interior to the ends of the side walls SW3 substantially completely. The rear side of the interior at the ends of the side walls SW3 can additionally be closed by a mold wall, which is required in particular when filling the interior of the profile by injection molding. The additional, the interior of the lens limiting shape walls can remain on the finished lamp or form parts of a reusable form.

The use of a prefabricated lens as part of a casting mold offers the possibility of using a material different from the casting material for the interior space for the area of the vehicle exterior light facing the surroundings. In particular, the lens LS or LP may consist of a material which has a higher impact strength and / or a higher scratch resistance and / or a lower roughness, etc., than the casting material. The potting material is permanently transparent and can be, for example, a thermoplastic, in particular a thermoplastic elastomer for filling the interior of the lens by injection molding. In another embodiment, in particular for the filling of the interior of the lens at atmospheric pressure, the potting material can advantageously be a starting material low-viscosity resin and / or polymer or a multi-component mixture, for example based on polyurethane and in the form partially formed by the lens according to different, known mechanisms solidify or by additional external influence, in particular thermal or electromagnetic radiation, for. As UV light, solidified.

In Fig. 4 is a sectional side view of a finished potted luminaire in Fig. 3 Outlined in parts sketched execution of a vehicle lamp. Light sources LQ with particularly high power dissipation can also be sunk in recesses of the board PL3 and thereby an improved thermal contact with the plate WS, which acts as a heat spreader with faster large-scale dissipation of heat loss stand.

In Fig. 5 is in an oblique view from the front and in Fig. 6 outlined in an oblique view from behind another advantageous embodiment of a vehicle lamp. This is similar to the execution Fig. 1 and Fig. 2 a board PL5 provided with a plurality of light sources LQ51, LQ52 for different lighting functions, from which a connecting cable KA is guided deflected backwards. On the back of the board PL5 is again provided a substantially rigid support BT with fasteners BE. The carrier BT can also serve at the same time for dissipation and areal distribution of waste heat from light sources on the front side of the circuit board PL5.

The outer shape of the lamp is similar to the embodiment according to Fig. 3 and Fig. 4 assumed in the manner of a profile with in a longitudinal direction constant cross section, from which mounting webs MS5 can stand for holding the lamp in a profile.

Unlike the previous embodiments, the luminaire contains Fig. 5 and Fig. 6 no separate lens. The entire luminaire body VK5 consists of material-homogeneous from a transparent potting compound, which board PL5 encloses all sides with light sources, lines, possibly further electronic components, cables and rear supports BT with fastening elements BE. For the production of the vehicle exterior light after Fig. 5 and Fig. 6 is a reusable form, which determines the outer shape of the luminaire prepared, in which the board is used with cable and back carrier with fasteners BE, the fasteners BE for the defined support of the unit PL5 board, KA cable and carrier BT in the Mold can be used.

A further advantageous embodiment of a vehicle lamp is in Fig. 7 with the components used in an oblique view and in Fig. 8 shown in the finished state in side view. The luminaire is essentially composed of a circular circuit board PL7 with a plurality of light-emitting diodes, which are divided into groups LQ71, LQ72 and LQ73, and a to be connected to the back of the board heat conduction plate WB made of aluminum, a cable KA and a composite in the above Condition enclosing body KP7 formed of potting material. To attach the finished lamp to a vehicle can be provided that threaded sleeves EH are fixed in the plate WB and projecting from this backwards and reach to the rear outer surface of the potting body KP7. In the Vergusskörper KP7 the positions of the individual, enclosed by the potting body KP7 in the finished state components of the lamp are located. Of course, the potting body does not exist as an independent part of the vehicle lamp, but is in Fig. 7 merely for the sake of clarity and completeness as an additional component. The potting occurs only as the other components enclosing body of potting on the finished light.

In the example of the vehicle exterior light after Fig. 7 and Fig. 8 the cable is guided from behind through the plate WB to the board PL7, for which in the plate WB a central recess KU is introduced, through which the strands liberated from the cable sheath of the connection cable KA are passed. From the side view Fig. 8 In particular, it can also be seen that the one-piece and material homogeneous body KP7 potting material continues on its back along the cable with a lug AK, which surrounds the cable KA in the sheathed area and by firm adhesion of the potting material on the cable sheath the cable ausziehsicher in the lamp body holds. Depending on the rigidity of the solidified potting material, the extension AK can also act as a type of kink protection for the cable KA.

A particularly advantageous embodiment of a vehicle exterior light is in Fig. 9 outlined. In this type of luminaire, the luminaire body is formed by an extruded plastic profile, in which light sources LQ9 and printed conductors SL are embedded fully encased in the plastic of the potting material. Such a vehicle exterior light is advantageously produced in such a way that a light source arrangement with the electrical conductors SL and light sources LQ and possibly other elements prepared and supplied during the extrusion process of the profile through the extrusion die, wherein during the extrusion process at the same time the supplied components fixed and substantially void-free Plastic are enclosed. The individual components to be coated are advantageously prepared band-shaped contiguous. In particular, the plurality of electrical lines SL may be mechanically interconnected in a band-shaped, preferably flexible carrier, wherein the flexible carrier may advantageously be designed as a flexible foil board or circuit board strip and may have further interconnects for contacting the light sources LQ9 with at least two of the lines LS. The lines SL can be made as one-piece strips solid metal or another electrically conductive material, in particular a conductive polymer, or in another embodiment of a plurality of metallic wires in the manner of a stranded be executed.

The lines SL of the line arrangements or at least a part of these lines are formed in an advantageous embodiment over the entire length of the lamp body formed by the extruded plastic profile. In a preferred embodiment, in a vehicle exterior light, in particular a side marker, within the extruded plastic profile more lines SL can be performed in the longitudinal direction as needed for the operation of the embedded light sources of this lamp. The luminaire can then at least partially take the place of a connecting cable for subsequent vehicle lights. Such a vehicle exterior light in the form of an extruded profile can also be designed in such a way that several different light function are embedded in a uniformly connected profile body.

In an advantageous further development, a vehicle lamp arrangement can also contain a plurality of longitudinally spaced apart side marker lamps along the longitudinal side of a vehicle and without interruption, a rear light assembly with preferably more tail light functions and be deflected without interruption around a corner of a vehicle or vehicle body structure within an integrally connected extruded profile. Such a profile can also continuously contain the side marker lights on both sides of a vehicle and at the rear of the vehicle without interruption continuously the rear light assembly of the vehicle and can also lead directly to a front-side electrical distributor of the vehicle in training in one-piece form, so that the vehicle lamp assembly to this extent without additional connecting cable can be executed and installed. In another embodiment, separate corner connectors between longitudinal lamp bodies and transverse to the longitudinal direction rear lights can be arranged at the corners.

The contacting of the lines SL for connection to an electrically supplying or continuing line can for example take place in that removed in an end region of the profile of the sheathed plastic and the tracks are exposed and connected in a conventional manner, for example by clamping or soldering to other lines. In another embodiment, a cable or a connection device, for. B. a plug connection to the band-shaped conductor carrier PB are connected before the production of the profile, which is then later freed from the sheath or not sheathed with. In yet another, preferred embodiment, the contacting of the individual lines SL through the plastic of the profile EP can be carried out by means of known tip contacting or cutting edge contacting.

The light sources LQ9, which are preferably embodied again as light-emitting diodes, are advantageously connected via additional electronic components, such as series resistors, regulators, limiters or the like, to lines SL of the line arrangement. The light sources LQ9 and the others, in Fig. 9 not shown with components can be arranged on a separate board PL9, which are electrically connected to the provided for the supply of these light sources lines SL of the line arrangement prior to casting. In another, preferred embodiment, the lines SL mechanically connecting, preferably flexible conductor carrier can be designed as board belt PB, on which even in a plane preferably separate from the lines SL board level Lines and connections for the light sources and wiring elements are prepared.

Can be connected to the line arrangement a light emitting surface LF9 of the profile facing reflector device RF, which may be formed, for example, as a reflective film or as a reflection coating. Such a reflection device can also be designed to be continuous and the light sources LQ9 surrounding.

The extruded profile advantageously has projections SV which face away from a rear attachment surface BF of the profile and which lie laterally of the light exit surface LF9 and project away from the rear side BF beyond the light exit surface LF9. The projections SV can thereby partially act as a mechanical protection of the light exit surface LF9. Such protective projections may also be provided in the other embodiments.

The profile EP can be attached, for example by sticking to a vehicle. In another embodiment, as outlined above, projecting projections FV can be provided on the profile upwards and downwards, with which the extruded profile is held in a holder provided on the vehicle, which in particular can also be a profile. In yet another, not drawn execution can be provided in the course of the profile, in particular transversely to the longitudinal direction of the light exit surface, attachment areas can be passed through which fasteners for attaching the vehicle exterior light on a vehicle.

In Fig. 10 is a first advantageous lighting arrangement of a vehicle, in particular a load trailer sketched in sections. The lighting arrangement includes a side marker lamp assembly SML of in Fig. 9 sketched type with an extruded profile as a lamp body and embedded light sources, reflector devices and a multi-core cable arrangement, wherein the line assemblies includes more wires than are required for the operation of the side marker lights. A tail light arrangement with a plurality of rear lights HL1, HL2 and HL3 is, for example, the type of in Fig. 3 sketched light with a molded multi-core connection cable VK executed. The tail lights HL1, HL2, HL3 can in particular the lighting functions, such as brake light, taillight, flashing light, reversing lights, work lights included and be designed as a one-piece light with one-piece or multi-part board or as cascaded individual lights. The tail light assembly can in particular also extend integrally over the entire vehicle width away and in the center of the vehicle a further light assembly HL4 with z. B. have additional warning lights, brake lights and / or license plate lights.

The connection cable VK preferably connected to the rear light assembly HL1 is led to the end of the profile of the side marker lights and there via a connection connector PVA, which in particular on the SML profile and / or on the connection cable via the insulation of conductor wires penetrating contact tips or contact blades is contacted , connected. In the course of the connection cable, a tracking light SL is connected via a further connection arrangement PVB without interruption of the connection cable VK, in particular again via a tip contact or edge contact in the connection arrangement PVB.

In Fig. 11 another embodiment of an advantageous vehicle lamp assembly is sketched in which a side marker lamp assembly SML of the in Fig. 9 sketched arrangement continuously in one piece around a corner of a vehicle in an area EB deflected and continued as a tail lamp assembly HL1, HL2, .... The tail lamp assembly may advantageously integrally formed over the entire width of the vehicle and at both rear corners of the vehicle integral with the side marker lamp assemblies form a continuous lamp body. The luminaire body can also be continued in the front area of the vehicle up to an electrical distributor, which is typically arranged at the vehicle center longitudinal plane.

At the in Fig. 11 sketched arrangement is still outlined an advantageous embodiment of a tracking light. While the side marker lights and the various tail lights typically radiate away from the vehicle perpendicular to the mounting surface of the profile on the vehicle, lane lights of different colors forward and rearward are provided as the main radiating directions. The tracking light in Fig. 11 is advantageously carried out as essay AL on the profile. In the profile are at the position of the article AL hidden electronic light sources with main radiation direction provided predominantly perpendicular to the mounting surface or to the longitudinal direction of the profile encapsulated in the lamp body provided. The attachment AL forms a passive optical module, in which the light emitted by the light sources embedded in the profile EP is deflected backwards or forwards.

The features indicated above and in the claims, as well as the features which can be seen in the figures, can be implemented advantageously both individually and in various combinations. The invention is not limited to those described Embodiments limited, but within the skill of the art in many ways changeable.

Claims (29)

1. Exterior vehicle luminaire with at least one electronic light source in a luminaire body and with a line arrangement with a plurality of electrical lines, the luminaire body being formed by a cast body made of an insulating casting compound, the light source and the lines being encapsulated by the cast body substantially free of cavities, and the casting compound being transparent at least in a main emission direction of the light source, characterized in that at least part of the outer surface of the cast body is covered by a protective layer made of a material which is different from the casting compound, the protective layer being formed by a housing shell, which is used as part of a casting mould for the cast body and remains on the cast body.
2. Exterior vehicle luminaire according to Claim 1, characterized in that the casting compound is also present on a rear side of the light source which is remote from the main emission direction.
3. Vehicle exterior luminaire according to Claim 1 or 2, characterized in that the casting compound surrounds the light source and the line arrangement on all sides with the exception of line connections which pass to the outside.
4. Exterior vehicle luminaire according to one of Claims 1 to 3, characterized in that the casting compound is permanently elastic in the solidified state.
5. Exterior vehicle luminaire according to one of Claims 1 to 4, characterized in that the casting compound is a thermoplastic material.
6. Exterior vehicle luminaire according to one of Claims 1 to 4, characterized in that the casting compound is an initially fluid, solidifiable material.
7. Exterior vehicle luminaire according to one of Claims 1 to 6, characterized in that at least some of the lines are mechanically connected in a line support.
8. Exterior vehicle luminaire according to Claim 7, characterized in that at least sections of the line support contain a substantially rigid board with conductor tracks.
9. Exterior vehicle luminaire according to Claim 7, characterized in that at least sections of the line support are flexible.
10. Exterior vehicle luminaire according to one of Claims 7 to 9, characterized in that the line support comprises a flexible strip with a plurality of lines.
11. Exterior vehicle luminaire according to Claim 10, characterized in that a substantially rigid board with conductor tracks bears the at least one light source and contact is made with it using lines of the flexible strip.
12. Exterior vehicle luminaire according to Claim 10 or 11, characterized in that a plurality of light sources are arranged spaced apart from one another along the strip and contact is made with them separately using lines of the flexible strip.
13. Exterior vehicle luminaire according to Claim 12, characterized in that the plurality of light sources are arranged on respectively dedicated boards.
14. Exterior vehicle luminaire according to one of Claims 1 to 13, characterized in that a plurality of luminaires which can be operated independently of one another and with dedicated light sources are arranged within a cast body.
15. Exterior vehicle luminaire according to one of Claims 1 to 14, characterized in that at least some of the lines of the line arrangements pass through the cast body between a line inlet and a line outlet.
16. Exterior vehicle luminaire according to Claim 15, characterized in that at least some of the lines passing through the cast body do not come into contact with any light source within the cast body.
17. Exterior vehicle luminaire according to one of Claims 1 to 16, characterized in that the cast body is delimited at least in the main light emission direction by a dimensionally stable, transparent housing shell.
18. Exterior vehicle luminaire according to one of Claims 1 to 17, characterized in that the outer surface demonstrates a uniform cross-sectional shape in a longitudinal direction running transversely with respect to the main light emission direction.
19. Exterior vehicle luminaire according to one of Claims 1 to 18, characterized in that the luminaire body has projections which protrude beyond the light exit face in the main light exit direction on at least two opposite sides of the light exit face.
20. Exterior vehicle luminaire according to one of Claims 1 to 19, characterized in that the luminaire body has fixing structures lying laterally on the outside and transversely with respect to the main light emission direction.
21. Exterior vehicle luminaire according to one of Claims 1 to 20, characterized in that the luminaire body is flexible.
22. Exterior vehicle luminaire according to one of Claims 1 to 21, characterized in that a reflector apparatus is enclosed in the cast body.
23. Exterior vehicle luminaire according to one of Claims 1 to 22, characterized in that fixing elements are embedded in the cast body.
24. Exterior vehicle luminaire according to one of Claims 1 to 23, characterized in that at least one light source is in the form of a light-emitting diode.
25. Method for manufacturing a vehicle luminaire arrangement according to one of Claims 1 to 24, a light source, with which contact is made using a multiple-core line arrangement, being inserted into a casting mould and the casting mould being filled with an electrically insulating, transparent casting material and the casting material being solidified, characterized in that a housing shell remaining on the solidified casting material is used as part of the casting mould.
26. Method according to Claim 25, characterized in that at least part of the line arrangement is passed to the outside out of the casting mould prior to the casting process.
27. Method according to one of Claims 25 to 26, characterized in that the casting material is introduced into the casting mould without any pressure being applied.
28. Method according to one of Claims 25 to 26, characterized in that the casting material is introduced into the casting mould under elevated pressure and elevated temperature.
29. Method for manufacturing a vehicle luminaire arrangement according to one of Claims 1 to 24, characterized in that the cast body is manufactured using the extrusion process and the light source is guided with the line arrangement in the extrusion direction through the extrusion die and extruded casting material is caused to flow around it.

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